Non-destructive ultrasonic inspection apparatus, systems, and methods

ABSTRACT

As described herein, a system for inspecting a component includes an ultrasonic inspection probe with a component surface interface, and a robotic device with an end effector coupled to the ultrasonic inspection probe. The robotic device is automatably controllable to move the ultrasonic inspection probe across a surface of the component. Additionally, the system includes an angle sensor subsystem coupled between the ultrasonic inspection probe and the end effector. The angle sensor subsystem is configured to operably detect an actual orientation of the end effector relative to a presently inspected portion of the surface of the component. The system includes a controller configured to receive orientation data from the angle sensor subsystem, the orientation data comprising the actual orientation of the end effector, compare the actual orientation to a desired orientation, and control the robotic device to adjust an orientation of the end effector to be in the desired orientation.

FIELD

This disclosure relates generally to detecting structuralcharacteristics of a component, and more particularly to detectingabnormalities or damage in a component using an ultrasonic inspectionprobe.

BACKGROUND

Structures experiencing loads or exposed to various environmentalfactors are susceptible to damage, such as cracking, corrosion,delamination, and the like. Additionally, some structures includeabnormalities formed during a manufacturing process. Damage to andabnormalities in structures may lead to aesthetic flaws, structuraldegradation, inefficiencies, poor performance, and even catastrophicfailure. Accordingly, the detection of damage to structures may bedesirable to mitigate or prevent the occurrence of such negativeconsequences. In some circumstances, the negative consequences of damageto the structure can be mitigated or prevented through detection andrepair of the damage.

Some structures include features that are particularly susceptible todamage. For example, cracks tend to form at and emanate from fastenerholes in surfaces of certain structures, such as aircraft.

SUMMARY

The subject matter of the present application has been developed inresponse to the present state of the art, and in particular, in responseto the problems associated with, and the need to, detect damage, such ascrack formations, and abnormalities, such as delamination or voids, invarious structures, including aircraft, that have not yet been fullysolved by currently available techniques. Accordingly, the subjectmatter of the present application has been developed to provide anapparatus, system, and method for detecting abnormalities and damage ina structure that overcome at least some of the above-discussedshortcomings of prior art techniques.

According to one embodiment, a system for inspecting a componentincludes an ultrasonic inspection probe that has a component surfaceinterface. The system also includes a robotic device with an endeffector coupled to the ultrasonic inspection probe. The robotic deviceis automatably controllable to move the ultrasonic inspection probeacross a surface of the component. Additionally, the system includes anangle sensor subsystem coupled between the ultrasonic inspection probeand the end effector. The angle sensor subsystem is configured tooperably detect an actual orientation of the end effector relative to apresently inspected portion of the surface of the component. The systemincludes a controller configured to receive orientation data from theangle sensor subsystem, the orientation data comprising the actualorientation of the end effector, compare the actual orientation to adesired orientation, and control the robotic device to adjust anorientation of the end effector to be in the desired orientation.

In one implementation of the system, the desired orientation isassociated with a longitudinal axis of the end effector beingperpendicular to the presently inspected portion of the surface of thecomponent.

According to one implementation, the system further includes anarticulation subsystem coupled between the inspection probe and the endeffector. The articulation subsystem is configured to operably maintainthe component surface interface properly engaged with the presentlyinspected portion of the surface of the component. The articulationsubsystem includes a two-axis gimbal structure coupled between theultrasonic inspection probe and the end effector in an implementation.The two-axis gimbal structure can be configured to passively absorbpitch and roll movement of the ultrasonic inspection probe. In animplementation, the articulation subsystem further includes a pneumaticactuator coupled between the two-axis gimbal structure and the endeffector. The pneumatic actuator is configured to passively absorbmovement of the ultrasonic inspection probe, via the two-axis gimbalstructure, along an axis substantially perpendicular to the presentlyinspected portion of the surface of the component. The angle sensorsubsystem includes a plurality of transducers coupled to the two-axisgimbal structure in an implementation. According to one implementation,the plurality of transducers includes a rotary variable differentialtransformer (RVDT) coupled to each axis of the two-axis gimbalstructure.

According to yet one implementation, the ultrasonic inspection probeincludes a housing, an ultrasonic array coupled to the housing, and acomponent surface interface of the housing. The component surfaceinterface includes a liquid couplant port, an engagement lip engageablewith a surface of the component, and at least one vacuum port. Theengagement lip circumferentially circumscribes the liquid couplant portand the at least one vacuum port circumferentially circumscribes theengagement lip. The at least one vacuum port is fluidly coupleable witha vacuum source. The ultrasonic inspection probe also includes a liquidcouplant chamber disposed between the ultrasonic array and the liquidcouplant port of the component surface interface. The liquid couplantchamber is in fluid communication with the liquid couplant port and theliquid couplant chamber is fluidly coupleable with a liquid couplantsupply. Additionally, the ultrasonic inspection probe includes anarticulation subsystem coupled to the housing and configured to operablymaintain the engagement lip of the component surface interface properlyengaged with the presently inspected portion of the surface of thecomponent.

In yet one embodiment, an apparatus for inspecting a component includesa housing, an ultrasonic array coupled to the housing, and a componentsurface interface of the housing. The component surface interfaceincludes a liquid couplant port, an engagement lip engageable with asurface of the component, and at least one vacuum port. The engagementlip circumferentially circumscribes the liquid couplant port and the atleast one vacuum port circumferentially circumscribes the engagementlip. The at least one vacuum port is fluidly coupleable with a vacuumsource. The apparatus also includes a liquid couplant chamber disposedbetween the ultrasonic array and the liquid couplant port of thecomponent surface interface. The liquid couplant chamber is in fluidcommunication with the liquid couplant port and the liquid couplantchamber is fluidly coupleable with a liquid couplant supply. Theapparatus further includes an articulation subsystem coupled to thehousing and configured to operably maintain the component surfaceinterface properly engaged with a presently inspected portion of thesurface of the component.

In one implementation, the apparatus defines a central axis extendingfrom the ultrasonic array and through the liquid couplant chamber andliquid couplant port. The articulation subsystem is configured tooperably maintain the central axis substantially perpendicular to thepresently inspected portion of the surface of the component. Accordingto an implementation, the liquid couplant chamber includes asubstantially uniform cross-sectional shape along the central axis andthrough the liquid couplant port.

According to one implementation, the engagement lip of the componentsurface interface is protruded relative to the at least one vacuum portso as to be positionable closer to the surface of the component relativeto the at least one vacuum port.

In an implementation, the housing is coupled to an end effector of arobotic device. The robotic device is automatably controllable to movethe apparatus across the surface of the component. The articulationsubsystem includes a two-axis gimbal structure coupled between thehousing and the end effector in one implementation. The two-axis gimbalstructure is configured to passively absorb pitch and roll movement ofthe housing. The articulation subsystem further includes a pneumaticactuator coupled between the two-axis gimbal structure and the endeffector. The pneumatic actuator is configured to passively absorbmovement of the housing, via the two-axis gimbal structure, along anaxis substantially perpendicular to the presently inspected portion ofthe surface of the component.

According to an implementation, the apparatus also includes an anglesensor subsystem coupled to the two-axis gimbal structure. The anglesensor subsystem is configured to detect an actual orientation of theend effector relative to the presently inspected portion of the surfaceof the component. The apparatus further includes a controller configuredto receive orientation data from the angle sensor subsystemcorresponding to the actual orientation of the end effector, compare theactual orientation to a desired orientation, and control the roboticdevice to adjust the actual orientation of the end effector to be in thedesired orientation. The desired orientation includes a longitudinalaxis of the end effector perpendicular to the presently inspectedportion of the surface of the component. The angle sensor subsystem maybe a plurality of transducers coupled to the two-axis gimbal structure.The plurality of transducers includes an RVDT coupled to each axis ofthe two-axis gimbal structure in one implementation.

According to another embodiment, a method for inspecting a componentincludes robotically moving an ultrasonic inspection probe across asurface of the component to inspect structural characteristics of thecomponent. Moving the ultrasonic inspection probe may includeautomatably controlling a robotic device with an end effector to whichthe ultrasonic inspection probe is coupled. The method includesdetecting an actual orientation of the end effector relative to apresently inspected portion of the surface of the component. Detectingthe actual orientation of the end effector includes receivingorientation data from an angle sensor subsystem that is coupled betweenthe ultrasonic inspection probe and the end effector. Additionally, themethod includes comparing the actual orientation to a desiredorientation, and controlling the robotic device to adjust the actualorientation of the end effector to be in the desired orientation.

In yet one embodiment, a controller for inspecting a component includesa movement module configured to implement a movement pattern of anultrasonic inspection probe across a surface of the component bycontrolling a robotic device with an end effector to which theultrasonic inspection probe is coupled. The controller includes a datamodule configured to receive structural characteristic data detected bythe ultrasonic inspection probe. Additionally, the controller includesan orientation module configured to detect an actual orientation of theend effector of the robotic device relative to a presently inspectedportion of the surface of the component, compare the actual orientationto a desired orientation, and control the robotic device to adjust theactual orientation of the end effector to be in the desired orientation.

According to an implementation, the controller further includes alearning module configured to incorporate predetermined orientationadjustments of the movement pattern at predetermined locations acrossthe surface of the component from a previously performed inspectionprocedure into the movement pattern.

The described features, structures, advantages, and/or characteristicsof the subject matter of the present disclosure may be combined in anysuitable manner in one or more embodiments and/or implementations. Inthe following description, numerous specific details are provided toimpart a thorough understanding of embodiments of the subject matter ofthe present disclosure. One skilled in the relevant art will recognizethat the subject matter of the present disclosure may be practicedwithout one or more of the specific features, details, components,materials, and/or methods of a particular embodiment or implementation.In other instances, additional features and advantages may be recognizedin certain embodiments and/or implementations that may not be present inall embodiments or implementations. Further, in some instances,well-known structures, materials, or operations are not shown ordescribed in detail to avoid obscuring aspects of the subject matter ofthe present disclosure. The features and advantages of the subjectmatter of the present disclosure will become more fully apparent fromthe following description and appended claims, or may be learned by thepractice of the subject matter as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the advantages of the subject matter may be more readilyunderstood, a more particular description of the subject matter brieflydescribed above will be rendered by reference to specific embodimentsthat are illustrated in the appended drawings. Understanding that thesedrawings depict only typical embodiments of the subject matter and arenot therefore to be considered to be limiting of its scope, the subjectmatter will be described and explained with additional specificity anddetail through the use of the drawings, in which:

FIG. 1A is a schematic block diagram of a system for inspecting acomponent, the system including an ultrasonic inspection probe, arobotic device, an angle sensor subsystem, and a controller, accordingto one embodiment;

FIG. 1B is a schematic block diagram of a system for inspecting acomponent the system including ultrasonic inspection probe, a roboticdevice, an articulation subsystem, an angle sensor subsystem, and acontroller, according to one embodiment;

FIG. 2 is a perspective view of a system for inspecting a component,according to one embodiment;

FIG. 3A is a partial perspective view of an end effector of a roboticdevice having an actual orientation that is different from a desiredorientation, according to one embodiment;

FIG. 3B is a partial perspective view of an end effector of a roboticdevice having an actual orientation that is the same as a desiredorientation, according to one embodiment;

FIG. 4 is a perspective view of an ultrasonic inspection probe coupledto an end effector of a robotic device and a pneumatic actuator of anarticulation subsystem, according to one embodiment;

FIG. 5 is a perspective view of a component surface interface of anultrasonic inspection probe and a two-axis gimbal structure of anarticulation subsystem, according to one embodiment;

FIG. 6A is a partial, cross-sectional perspective view of an ultrasonicinspection probe having a liquid couplant chamber, according to oneembodiment;

FIG. 6B is a cross-sectional view of an ultrasonic inspection probehaving an engagement lip proximate a surface of a component, accordingto one embodiment;

FIG. 7A is a schematic block diagram of a controller for controlling aninspection of a component, according to one embodiment;

FIG. 7B is a schematic block diagram of a controller for controlling aninspection of a component, according to another embodiment;

FIG. 8 is a schematic flow chart diagram of a method for inspecting acomponent, according to one embodiment;

FIG. 9 is a flow diagram of aircraft production and service methodology;and

FIG. 10 is a block diagram of an aircraft.

DETAILED DESCRIPTION

Reference throughout this specification to “one embodiment,” “anembodiment,” or similar language means that a particular feature,structure, or characteristic described in connection with the embodimentis included in at least one embodiment of the present disclosure.Appearances of the phrases “in one embodiment,” “in an embodiment,” andsimilar language throughout this specification may, but do notnecessarily, all refer to the same embodiment. Similarly, the use of theterm “implementation” means an implementation having a particularfeature, structure, or characteristic described in connection with oneor more embodiments of the present disclosure, however, absent anexpress correlation to indicate otherwise, an implementation may beassociated with one or more embodiments.

FIG. 1A is a schematic block diagram of a system 100 for inspecting acomponent. The component 50 to be inspected may be or form part of anyof various structures, such as a vehicle, a building, a bridge, andaircraft, etc. According to one embodiment, the system 100 includes anultrasonic inspection probe 110, a robotic device 120, an angle sensorsubsystem 130, and a controller 150. Generally, the ultrasonicinspection probe 110 is coupled to the robotic device 120 and therobotic device 120 is controlled by the controller 150 to position theultrasonic inspection probe 110 in a desired inspection positionrelative to a surface of the component being inspected. The angle sensorsubsystem 130 is configured to monitor the angular position of theinspection probe 110 in order to maintain the inspection probe 110 inthe desired position. Once the ultrasonic inspection probe 110 is in thedesired inspection position, the controller 150 actuates the roboticdevice 120 in order to move the ultrasonic inspection probe 110 alongand across surface of the component (as described in greater detail withrespect to FIG. 2).

FIG. 1B is a schematic block diagram of another embodiment of a system101 for inspecting a component, the system 101 including the ultrasonicinspection probe 110, the robotic device 120, the angle sensor subsystem130, an articulation subsystem 140, and the controller 150. Theinspection probe 110, the robotic device 120, the angle sensor subsystem130, and the controller 150 may be substantially the same as describedabove with reference to FIG. 1A. The articulation subsystem 140,according to one embodiment, is configured to further facilitate themaintenance of the proper position of the ultrasonic inspection probe110. The articulation subsystem 140, as described in greater detailbelow with reference to FIGS. 4 and 5, dampens and/or absorbs certainfeatures or irregularities in the surface of the component beinginspected in order to allow the ultrasonic inspection probe 110 toremain properly engaged on the surface of the component.

FIG. 2 is a perspective view of one embodiment of the system 102 forinspecting the component 50. Referring to FIG. 2, the system 102includes the ultrasonic inspection probe 110, which is coupled to therobotic device 120. The robotic device 120 can be controlled by thecontroller 150. More specifically, the robotic device 120 is controlledby the controller 150 to position the ultrasonic inspection probe 110 ina desired inspection position relative to a surface 51 of the component50 in order to non-destructively inspect the structure. As describedbelow and according to one embodiment, the desired inspection positioncan be a position in which an ultrasonic transducer array of theultrasonic inspection probe 110 is perpendicular to the outer surface 51of the component. With the ultrasonic inspection probe 110 in thedesired inspection position, the robotic device 120, actuated by thecontroller 150, operably moves the ultrasonic inspection probe 110 alongand across the surface 51 of the component 50.

As described in greater detail below with reference to FIGS. 6A and 6B,the ultrasonic array housed within ultrasonic inspection probe 110transmits an ultrasonic signal directed at the component 50. In oneembodiment, the ultrasonic inspection probe 110 further includes meansfor utilizing a liquid couplant, such as water, oil, propylene glycol,glycerin, gel, and the like, to facilitate and promote the transmissionand propagation of the ultrasonic signal/waves.

The controller 150, as depicted in FIG. 2, is coupled to the roboticdevice 120. In another embodiment, the controller 150 may be integratedor coupled to a computer or a computer network that is electronicallycoupled to the robotic device 120. In a further embodiment, thecontroller 150 may have various modules that are implemented usingvarious electronic devices. Additional details relating to thecontroller 150 are included below with reference to FIGS. 7A and 7B. Asdepicted in FIG. 2, the robotic device 120 may be a robotic arm that isrotatable, pivotable, and/or extendable in a variety of differentmanners in order to position the ultrasonic inspection probe 110 in aplurality of positions. For example, in one embodiment the roboticdevice 120 is a robotic arm manufactured by Kuka®.

The component 50 can be any of various components made from any ofvarious materials. In some implementations, the component 50 is madefrom a metal, such as steel and aluminum. In other implementations, thecomponent 50 is made from a non-metal, such as graphite, composite,ceramic, polymer, and the like. In one embodiment, the component has a3-dimensional structure that can be any of various 3-dimensionalstructures. For example, the component 50 may be non-flat orsubstantially curved and/or may include one or more protrusions thatprotrude relative to a flat or substantially non-flat plane ofreference. Additionally, the component 50 may be double-sided and thesystem 102 may be configured to inspect both sides of the component 50.

FIG. 3A is a partial perspective view of one embodiment of an endeffector 122 of the robotic device 120, with the end effector beinghaving an actual orientation that is different from a desiredorientation. FIG. 3B is a partial perspective view of the end effector122 of the robotic device 120 having an actual orientation that is thesame as the desired orientation. The ultrasonic inspection probe 110 iscoupled to the end effector 122 of the robotic device 120. Uponoperation, the ultrasonic inspection probe 110 moves across the surface51 of the component 50. During operation, the region or portion of thesurface 51 of the component 50 that is instantaneously inspected isreferred to herein as the presently inspected portion 52 of thecomponent 50. FIGS. 3A and 3B show three coordinate axis 53, 54, 55relative to the presently inspected portion 52. Two of the axis, thex-axis 54 and the y-axis 55, extend in their respective directionssubstantially tangentially from the presently inspected portion 52 ofthe component 50. The normal axis 53 extends perpendicularly away fromthe x-axis 54 and y-axis 55.

In one embodiment, the end effector 122 and the coupled ultrasonicinspection probe 110 desirably remain in a substantially perpendicularorientation, with respect to the presently inspected portion 52 of thecomponent 50, as the ultrasonic inspection probe 110 moves across andalong the surface 51 of the component 50. In other words, the systemincludes the angle sensor subsystem 130 in order to maintain alongitudinal axis 123 of the end effector 122 of the robotic device 120in a desired orientation relative to the presently inspected portion 52of the component 50. For example, in one embodiment the desiredorientation is substantially parallel to the normal axis 53 (i.e.,perpendicular to the tangential coordinate axis 54, 55). FIG. 3A showsan angle 124 between the longitudinal axis 123 of the end effector 122of the robotic device 120 and the normal axis 53. In such an embodiment,the actual position of the end effector 122 of the robotic device 120 isdifferent from the desired orientation. Accordingly, the systemincludes, according to one embodiment, the angle sensor subsystem 130.As described below, the angle sensor subsystem 130 is configured todetect the offset orientation of the end effector 122 and report such anoffset to the controller 150. The controller 150 is then able to sendactuation commands to the robotic device 120 to reposition and/orreorient the robotic device 120, specifically the end effector 122 ofthe robotic device 120, so that the longitudinal axis 123 issubstantially parallel to the normal axis 53, as depicted in FIG. 3B.

As described above, the robotic device may be pivotable, rotatable, andextendable. Accordingly, depending on the detected actual orientation ofthe end effector 122 relative to the presently inspected portion 52 ofthe surface 51 of the component and the offset between the actualorientation and the desired orientation, the controller 150 may sendvarious actuation commands to the robotic device 120 in order to correctthe actual orientation of the end effector 122 (i.e., actuate therobotic device 120 so that the actual orientation matches the desiredorientation). The type of adjustments to the orientation of the endeffector 122 may include lateral adjustments, pitch adjustments, rolladjustments, extension adjustments, and height adjustments, amongothers.

The angle sensor subsystem 130 may include various sensors and/ortransducers that detect the actual orientation of the end effector 122with respect to the presently inspected portion 52 of the component andreport any difference between the actual orientation and the desiredorientation of the end effector 122. For example, in one embodiment theangle sensor subsystem 130 includes a rotary variable differentialtransformer (RVDTs). An RVDT is a type of electrical transformer thatdetects and/or measures angular displacement. Accordingly, in oneembodiment, the system 100 may include one or more RVDTs coupled at thepoint(s) where the end effector 122 is coupled to the ultrasonicinspection probe 110. In another embodiment, the angle sensory subsystem130 may include other sensors that are capable of detecting the angledorientation of an object with respect to another object (i.e., a surfaceof the object). For example, an optical sensor mechanism may beimplemented to detect the actual orientation of the end effector 122with respect to the presently inspected portion 52 of the component 50.

FIG. 4 is a perspective view of one embodiment of the ultrasonicinspection probe 110 coupled to the end effector 122 of the roboticdevice 120 and a pneumatic actuator 145 of an articulation subsystem140. In one embodiment, the ultrasonic inspection probe 110 may employ aliquid couplant between the ultrasonic array housed within the housing111 and the surface of the component being inspected. Accordingly,various tubes, pipes, and/or manifold assemblies 60 handling the liquidcouplant may be included with or coupleable with the ultrasonicinspection probe 110. Additionally, included with or coupleable with theultrasonic inspection probe 110 may be vacuum lines and/or a vacuumsource for vacuuming excess liquid couplant. The liquid couplanttransmission lines and/or the vacuum lines may include one or moreliquid couplant ports and one or more vacuum ports disposed on acomponent surface interface 114 of the ultrasonic inspection probe 110.Details relating to one specific embodiment of an ultrasonic inspectionprobe that utilizes a liquid couplant in a vacuum system are includedbelow with reference to FIGS. 5-6B.

In one embodiment, the system for inspecting the component may alsoinclude an articulation subsystem. The articulation subsystem may beconfigured to dampen and/or absorb the effect that certain features orirregularities in the surface of the component 50 have on inspectionprocess. For example, when a column of liquid couplant is employedbetween the ultrasonic inspection probe 110 and the surface 51 of thecomponent 50 to promote the propagation and transmission of anultrasonic signal, it may be beneficial for the component surfaceinterface 114 to remain substantially parallel to the presentlyinspected portion 52 of the surface 51 of the component 50 in order tomaintain a consistent column of liquid couplant (i.e., prevent excessiveliquid couplant leakage).

In one embodiment, the articulation subsystem may include a passiveactuator that absorbs unwanted and/or unexpected movement along thelongitudinal axis 123 of the end effector 122. For example, as depictedin FIG. 4, a pneumatic actuator 145 may be coupled between the endeffector 122 in the ultrasonic inspection probe 110. In such anembodiment, the pneumatic actuator 145 helps to maintain the componentsurface interface 114 of the ultrasonic inspection probe 110appropriately engaged on the surface 51 of the component 50. Thearticulation subsystem may further include assemblies and/or mechanismsthat dampen pitch and roll type movement of the ultrasonic inspectionprobe 110 (e.g., a gimbal structure).

FIG. 5 is a perspective view of one embodiment of a component surfaceinterface 114 of the ultrasonic inspection probe 110 and an articulationsubsystem that includes a two-axis gimbal structure 142. The gimbalstructure 142, according to one embodiment, includes a first axis 143and a second axis 144 that dampen and/or absorb pitch and roll typemovement of the component surface interface 114 of the ultrasonicinspection probe 110. As defined herein, the component surface interface114 of the ultrasonic inspection probe 110 is this section/surface ofthe ultrasonic inspection probe that engages or at least faces thepresently inspected portion 52 of the surface 51 of the component 50.

In the depicted embodiment, the component surface interface 114 includesa couplant port 115 and at least one vacuum port 117. In one embodiment,the component surface interface 114 further includes an engagement lip116 that circumferentially circumscribes the liquid couplant port 115.The engagement lip 116 is defined herein as the surface that engages thepresently inspected portion 52 of the surface 51 of the component andprevents excessive liquid couplant leakage from a liquid couplantchamber (not shown in FIG. 5) of the housing 111 of the ultrasonicinspection probe 110. In one embodiment the housing 111, or at least aportion of the housing 111 such as the engagement lip 116, is made froma compliant material that flexes when engaged upon the surface 51 of thecomponent 50. In such an embodiment, the flexing nature of theengagement lip 116 promotes the proper engagement between the surface 51of the component 50 and the ultrasonic inspection probe 110, therebypreventing excessive liquid couplant leakage and improving the accuracyof the ultrasonic inspection technique. Accordingly, according to oneembodiment, the engagement lip 116 circumferentially circumscribes theliquid couplant port 115 and the at least one vacuum port 117circumferentially circumscribes the engagement lip 116. In such anembodiment, any liquid couplant that leaks between the engagement lip116 and the surface 51 of the component 50 is suctioned through the atleast one vacuum port 117 to prevent liquid couplant from runningdown/across the surface 51 of the component 50 and to maintain thesurface 51 of the component 50 substantially dry and free from excessiveliquid couplant. In one embodiment, when the surface 51 of the component50 is substantially dry and free from excessive liquid couplant,subsequent inspection procedures and/or subsequentmanufacturing/assembly procedures may be more easily implemented withthe component 50 because there is no need to air dry and/or clean thesurface 51 of the component 50.

As briefly described above, RVDTs, or other such devices, may be coupledto the first axis 143 and/or second axis 144 of the gimbal structure todetect the angled orientation of the end effector 122 of the roboticdevice 120 with respect to the presently inspected portion 52 of thesurface 51 of the component 50. For example, the component surfaceinterface 114 of the ultrasonic inspection probe 110 may still bemaintained substantially parallel to the presently inspected portion 52of the surface 51 of the component 50 via the gimbal structure 142 evenwhen the longitudinal axis 123 of the end effector 122 of the roboticdevice 120 is not perpendicular to the presently inspected portion 52 ofthe surface 51 of the component 50. However, the angle sensor subsystem130 may detect the non-perpendicular longitudinal axis 123 of the endeffector 122 and may send such a notification to the controller 150. Thecontroller 150 may then send actuation commands to the robotic device120 to adjust the position and orientation of the end effector 122.

FIG. 6A is a partial, cross-sectional perspective view of one embodimentof the ultrasonic inspection probe 110 having a liquid couplant chamber113 and FIG. 6B is a cross-sectional view of the ultrasonic inspectionprobe having the engagement lip 116 proximate the presently inspectedportion 52 of the surface 51 of the component 50. In the depictedembodiment, the ultrasonic inspection probe 110 includes a housing 111within which an ultrasonic array 112 is housed. The housing 111 of theultrasonic inspection probe 110 further includes a liquid couplantchamber 113 disposed between the ultrasonic array 112 and the componentsurface interface 114. Although not depicted, the housing 111 mayinclude liquid couplant supply lines, coupleable with a liquid couplantsupply source, that operably deliver liquid couplant to the liquidcouplant chamber 113. In one embodiment, the liquid couplant chamber 113is maintained at a positive pressure in order to promote auniform/consistent propagation medium for the ultrasonic signal. Asdescribed above, during operation of the ultrasonic inspection probe110, a substantially uniform column of liquid couplant 119 may bemaintained within the liquid couplant chamber 113, thereby facilitatingthe transmission and propagation of an ultrasonic signal 108 between theultrasonic array 112 and the presently inspected portion 52 of thesurface 51 of the component 50.

The ultrasonic array 112 may include multiple wave transducers that canbe any of various wave transducers for emitting and receiving ultrasonicsignals 108. According to some embodiments, the wave transducers of theultrasonic array 112 emit and receive ultrasonic waves. Generally, theultrasonic signal 108 generated and emitted by the ultrasonic array aretransmitted into the component 50. After passing through the column ofliquid couplant 119, the ultrasonic signal 108 propagates through thecomponent 50 from the outer surface 51 (e.g., front surface) to anopposing back surface. Portions of the signal 108 may reflect off theouter surface 51, the inner structure, and the back surface of thecomponent 50. The reflected waves pass through the column of liquidcouplant and are received by the wave transducers of the ultrasonicarray 112. The pulse characteristics (e.g., amplitude) of the ultrasonicsignal 108 generated by the wave ultrasonic array 112 are compared tothe pulse characteristics of the reflected waves received by theultrasonic array (e.g. after passing through the component 50) todetermine if defects exist in the structure. The type of wavetransducers utilized for a specific embodiment of the ultrasonic arraymay be selected according to the type of structure that is beinginspected. For example, certain wave transducers may be comparativelybetter-suited for metallic structures while other wave transducers maybe comparatively better-suited for composite structures.

The engagement lip 116, according to one embodiment, may be slightlyprotruded so as to be comparatively closer to the surface 51 of thecomponent 50 then the vacuum ports 117. As described above, the vacuumports 117 are fluidly coupled to the interior vacuum cavity 118 withinthe housing 111 of the ultrasonic inspection probe 110. The number,size, configuration, shape, and dimensions of the vacuum ports 117 maybe selected according to the specifics of a given application.

According to one embodiment, the maintenance of the proper orientationof the ultrasonic inspection probe 110 with respect to the presentinspected portion 52 of the surface 51 of the component 50 is importantto an accurate inspection. Accordingly, the angle sensor subsystem 130and the articulation subsystem 140 may both be implemented to facilitatemaintaining the proper orientation of the ultrasonic inspection probe110. Not only with the proper orientation of the ultrasonic inspectionprobe 110 prevent leakage of liquid couplant 119, the detection ofstructural characteristic data relating to the reflected waves from aproperly oriented ultrasonic inspection probe will be comparatively moreaccurate. In other words, an ultrasonic inspection probe that is offsetfrom a desire orientation may potentially result in any accurate and/orskewed structural characteristic data of the component 50.

A central axis 109 extends from the ultrasonic array 112 through theliquid couplant chamber 113 and the liquid couplant port 115. In oneembodiment, the proper position of the ultrasonic inspection probe 110is when the central axis 109 is substantially perpendicular to thepresently inspected portion 52 of the surface 51 of the component 50.Put differently, in the proper position the central axis 109 is parallelto the normal axis 53 shown in FIGS. 3A and 3B.

Generally, the articulation subsystem 140 maintains proper engagementbetween the component surface interface 114 of the ultrasonic inspectionprobe 110 despite inconsistencies/irregularities in the surface 51 ofthe component 50 and the angle sensor subsystem 130 actively detectsoffsets between an actual orientation of the end effector 122 of therobotic device 120 and, via the controller 150, actively actuates therobotic device 120 to adjust the actual orientation of the end effector122 to be in the desired orientation. With one or both of thesubsystems, the ultrasonic inspection probe 110 of the presentdisclosure is able to, when compared with most conventional inspectiondevices, move across the surface 51 of the component 50 at acomparatively higher speed while still maintaining the properposition/orientation of the ultrasonic inspection probe 110.

FIG. 7A is a schematic block diagram of one embodiment of the controller150 for controlling an inspection of the component 50. The controller150, according to one embodiment, includes a movement module 152, a datamodule 154, and an orientation module 156. The movement module 152 isconfigured to implement a movement pattern of the ultrasonic inspectionprobe 110 across a surface 51 of the component 50 by controlling therobotic device 120, with the ultrasonic inspection probe 110 coupled tothe end effector 122. The movement module 152 may includepreprogrammed/predetermined movement patterns and associated roboticalgorithms for actuating the movement pattern with robotic device.

The data module 154 is configured to receive structural characteristicdata detected by the ultrasonic inspection probe 110. In other words,the data module 154 receives output signals from the ultrasonic array112. According to some embodiments, the data module 154, or separateanalysis module (not shown), utilizes the structural characteristic datato detect the presence of damage in the structure of the component 50.The data module 154 can use any of various methods and/or apply any ofvarious algorithms for detecting damage based on the sensed structuralcharacteristic data. In certain embodiments, the data module 154 detectsdamage to the structure by applying the sensed structural characteristicdata to a baseline-less model without relying on predetermined or knownbaselines.

However, in yet some embodiments, the data module 154 detects damage byapplying the structural characteristic data to a baseline model byrelying on predetermined or known baseline waveforms. For example, inone embodiment, the data module 154 compares the structuralcharacteristic data with expected data or baseline to detect thepresence of damage in the structure of the component 50. Accordingly,variations in the structural characteristic data compared to theexpected data indicates abnormalities or damage (e.g., cracking) in thestructure of the component 50.

The orientation module 156 is configured to detect the actualorientation of the end effector 122 relative to the presently inspectedportion 52 of the surface 51 of the component 50 based on the sensedstructural characteristic data. Once the actual orientation of the endeffector 122 is determined, the orientation module 156 compares theactual orientation to the desired orientation sends actuation commandsto the robotic device 120 to adjust the actual orientation of the endeffector 122 so as to be in the desired orientation.

As depicted in FIG. 7B, in one embodiment the controller 151 may includethe previously described modules 152, 154, 156 in addition to a learningmodule 158. The learning module 158 may be configured to incorporatepredetermined orientation adjustments to the end effector 122 relativeto predetermined locations across the surface of the component from apreviously performed inspection procedure on the component into themovement pattern of the movement module. In other words, the learningmodule 158 may interact with the movement module 152 to change/alter themovement pattern in the movement algorithms that is sent to the roboticdevice 120 in order to improve the positioning accuracy of the endeffector 122 of the robotic device 120.

FIG. 8 is a schematic flow chart diagram of one embodiment of a method200 for inspecting the component. According to one embodiment, themethod 200 for detecting damage in a structure can be executed by thesystems and apparatus described herein, or other systems and apparatus.The method 200 includes robotically moving an ultrasonic inspectionprobe across a surface of the component to inspect structuralcharacteristics of the component at 210. In one embodiment, moving theultrasonic inspection probe includes automatably controlling a roboticdevice having an end effector to which the ultrasonic inspection probeis coupled.

The method 200 further includes detecting an actual orientation of theend effector relative to a presently inspected portion of the surface ofthe component at 220. According to one embodiment, detecting the actualorientation of the end effector includes receiving orientation data froman angle sensor subsystem that is coupled between the ultrasonicinspection probe and the end effector. The method 200 further includescomparing the actual orientation of the end effector to a desiredorientation at 230 and controlling the robotic device to adjust theactual orientation of the end effector to be in the desired orientationat 240.

In one embodiment, the method 200 may further include adjusting theactual orientation of the end effector according to predeterminedorientation adjustments at predetermined locations across the surface ofthe component from a previously performed inspection of the component.For example, the controller may have detected, from a previouslyperformed inspection of a component (e.g., an aircraft),locations/points across the surface of the component that requiredactive adjustment to the actual orientation of the end effector. Suchadjustments at such locations/points may be incorporated into thecontrol scheme of subsequent inspection procedures of the same (or atleast substantially similar component) to improve the positioning andorientation of the end effector.

Referring more particularly to the drawings, embodiments of thedisclosure may be described in the context of an aircraft manufacturingand service method 400 as shown in FIG. 9 and an aircraft 402 as shownin FIG. 10. During pre-production, exemplary method 400 may includespecification and design 404 of the aircraft 402 and materialprocurement 406. During production, component and subassemblymanufacturing 408 and system integration 410 of the aircraft 402 takesplace. Thereafter, the aircraft 402 may go through certification anddelivery 412 in order to be placed in service 414. While in service by acustomer, the aircraft 402 is scheduled for routine maintenance andservice 416 (which may also include modification, reconfiguration,refurbishment, and so on).

Each of the processes of method 400 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may includewithout limitation any number of aircraft manufacturers and major-systemsubcontractors; a third party may include without limitation any numberof venders, subcontractors, and suppliers; and an operator may be anairline, leasing company, military entity, service organization, and soon.

As shown in FIG. 10, the aircraft 402 produced by exemplary method 400may include an airframe 418 with a plurality of systems 420 and aninterior 422. Examples of high-level systems 420 include one or more ofa propulsion system 424, an electrical system 426, a hydraulic system426, and an environmental system 430. Any number of other systems may beincluded. Although an aerospace example is shown, the principles of theinvention may be applied to other industries, such as the automotiveindustry.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of the production and service method 400. Forexample, components or subassemblies corresponding to production process408 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 402 is in service. Also,one or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized during the production stages 408 and 410, forexample, by substantially expediting assembly of or reducing the cost ofan aircraft 402. Similarly, one or more of apparatus embodiments, methodembodiments, or a combination thereof may be utilized to detect crackformations while the aircraft 402 is in service, for example and withoutlimitation, to maintenance and service 416.

In the above description, certain terms may be used such as “up,”“down,” “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,”“over,” “under” and the like. These terms are used, where applicable, toprovide some clarity of description when dealing with relativerelationships. But, these terms are not intended to imply absoluterelationships, positions, and/or orientations. For example, with respectto an object, an “upper” surface can become a “lower” surface simply byturning the object over. Nevertheless, it is still the same object.Further, the terms “including,” “comprising,” “having,” and variationsthereof mean “including but not limited to” unless expressly specifiedotherwise. An enumerated listing of items does not imply that any or allof the items are mutually exclusive and/or mutually inclusive, unlessexpressly specified otherwise. The terms “a,” “an,” and “the” also referto “one or more” unless expressly specified otherwise. Further, the term“plurality” can be defined as “at least two.”

Additionally, instances in this specification where one element is“coupled” to another element can include direct and indirect coupling.Direct coupling can be defined as one element coupled to and in somecontact with another element. Indirect coupling can be defined ascoupling between two elements not in direct contact with each other, buthaving one or more additional elements between the coupled elements.Further, as used herein, securing one element to another element caninclude direct securing and indirect securing. Additionally, as usedherein, “adjacent” does not necessarily denote contact. For example, oneelement can be adjacent another element without being in contact withthat element.

As used herein, the phrase “at least one of”, when used with a list ofitems, means different combinations of one or more of the listed itemsmay be used and only one of the items in the list may be needed. Theitem may be a particular object, thing, or category. In other words, “atleast one of” means any combination of items or number of items may beused from the list, but not all of the items in the list may berequired. For example, “at least one of item A, item B, and item C” maymean item A; item A and item B; item B; item A, item B, and item C; oritem B and item C. In some cases, “at least one of item A, item B, anditem C” may mean, for example, without limitation, two of item A, one ofitem B, and ten of item C; four of item B and seven of item C; or someother suitable combination.

Unless otherwise indicated, the terms “first,” “second,” etc. are usedherein merely as labels, and are not intended to impose ordinal,positional, or hierarchical requirements on the items to which theseterms refer. Moreover, reference to, e.g., a “second” item does notrequire or preclude the existence of, e.g., a “first” or lower-numbereditem, and/or, e.g., a “third” or higher-numbered item.

As will be appreciated by one skilled in the art, aspects of the presentdisclosure can be embodied as a system, method, and/or computer programproduct. Accordingly, aspects of the present disclosure may take theform of an entirely hardware embodiment, an entirely software embodiment(including firmware, resident software, micro-code, etc.) or anembodiment combining software and hardware aspects that may allgenerally be referred to herein as a “circuit,” “module,” or “system.”Furthermore, aspects of the present disclosure may take the form of acomputer program product embodied in one or more computer readablemedium(s) having program code embodied thereon.

Many of the functional units described in this specification have beenlabeled as modules, in order to more particularly emphasize theirimplementation independence. For example, a module may be implemented asa hardware circuit comprising custom VLSI circuits or gate arrays,off-the-shelf semiconductors such as logic chips, transistors, or otherdiscrete components. A module may also be implemented in programmablehardware devices such as field programmable gate arrays, programmablearray logic, programmable logic devices or the like.

Modules may also be implemented in software for execution by varioustypes of processors. An identified module of program code may, forinstance, comprise one or more physical or logical blocks of computerinstructions which may, for instance, be organized as an object,procedure, or function. Nevertheless, the executables of an identifiedmodule need not be physically located together, but may comprisedisparate instructions stored in different locations which, when joinedlogically together, comprise the module and achieve the stated purposefor the module.

Indeed, a module of program code may be a single instruction, or manyinstructions, and may even be distributed over several different codesegments, among different programs, and across several memory devices.Similarly, operational data may be identified and illustrated hereinwithin modules, and may be embodied in any suitable form and organizedwithin any suitable type of data structure. The operational data may becollected as a single data set, or may be distributed over differentlocations including over different storage devices, and may exist, atleast partially, merely as electronic signals on a system or network.Where a module or portions of a module are implemented in software, theprogram code may be stored and/or propagated on in one or more computerreadable medium(s).

The computer readable medium may be a tangible computer readable storagemedium storing the program code. The computer readable storage mediummay be, for example, but not limited to, an electronic, magnetic,optical, electromagnetic, infrared, holographic, micromechanical, orsemiconductor system, apparatus, or device, or any suitable combinationof the foregoing.

More specific examples of the computer readable storage medium mayinclude but are not limited to a portable computer diskette, a harddisk, a random access memory (RAM), a read-only memory (ROM), anerasable programmable read-only memory (EPROM or Flash memory), aportable compact disc read-only memory (CD-ROM), a digital versatiledisc (DVD), an optical storage device, a magnetic storage device, aholographic storage medium, a micromechanical storage device, or anysuitable combination of the foregoing. In the context of this document,a computer readable storage medium may be any tangible medium that cancontain, and/or store program code for use by and/or in connection withan instruction execution system, apparatus, or device.

The computer readable medium may also be a computer readable signalmedium. A computer readable signal medium may include a propagated datasignal with program code embodied therein, for example, in baseband oras part of a carrier wave. Such a propagated signal may take any of avariety of forms, including, but not limited to, electrical,electro-magnetic, magnetic, optical, or any suitable combinationthereof. A computer readable signal medium may be any computer readablemedium that is not a computer readable storage medium and that cancommunicate, propagate, or transport program code for use by or inconnection with an instruction execution system, apparatus, or device.Program code embodied on a computer readable signal medium may betransmitted using any appropriate medium, including but not limited towire-line, optical fiber, Radio Frequency (RF), or the like, or anysuitable combination of the foregoing.

In one embodiment, the computer readable medium may comprise acombination of one or more computer readable storage mediums and one ormore computer readable signal mediums. For example, program code may beboth propagated as an electro-magnetic signal through a fiber opticcable for execution by a processor and stored on RAM storage device forexecution by the processor.

Program code for carrying out operations for aspects of the presentdisclosure may be written in any combination of one or more programminglanguages, including an object oriented programming language such asJava, Smalltalk, C++, PHP or the like and conventional proceduralprogramming languages, such as the “C” programming language or similarprogramming languages. The program code may execute entirely on theuser's computer, partly on the user's computer, as a stand-alonesoftware package, partly on the user's computer and partly on a remotecomputer or entirely on the remote computer or server. In the latterscenario, the remote computer may be connected to the user's computerthrough any type of network, including a local area network (LAN) or awide area network (WAN), or the connection may be made to an externalcomputer (for example, through the Internet using an Internet ServiceProvider).

The computer program product may be stored on a shared file systemaccessible from one or more servers. The computer program product may beexecuted via transactions that contain data and server processingrequests that use Central Processor Unit (CPU) units on the accessedserver. CPU units may be units of time such as minutes, seconds, hourson the central processor of the server. Additionally the accessed servermay make requests of other servers that require CPU units. CPU units arean example that represents but one measurement of use. Othermeasurements of use include but are not limited to network bandwidth,memory usage, storage usage, packet transfers, complete transactions,etc.

Aspects of the embodiments may be described above with reference toschematic flowchart diagrams and/or schematic block diagrams of methods,apparatuses, systems, and computer program products according toembodiments of the disclosure. It will be understood that each block ofthe schematic flowchart diagrams and/or schematic block diagrams, andcombinations of blocks in the schematic flowchart diagrams and/orschematic block diagrams, can be implemented by program code. Theprogram code may be provided to a processor of a general purposecomputer, special purpose computer, sequencer, or other programmabledata processing apparatus to produce a machine, such that theinstructions, which execute via the processor of the computer or otherprogrammable data processing apparatus, create means for implementingthe functions/acts specified in the schematic flowchart diagrams and/orschematic block diagrams block or blocks.

The program code may also be stored in a computer readable medium thatcan direct a computer, other programmable data processing apparatus, orother devices to function in a particular manner, such that theinstructions stored in the computer readable medium produce an articleof manufacture including instructions which implement the function/actspecified in the schematic flowchart diagrams and/or schematic blockdiagrams block or blocks.

The program code may also be loaded onto a computer, other programmabledata processing apparatus, or other devices to cause a series ofoperational steps to be performed on the computer, other programmableapparatus or other devices to produce a computer implemented processsuch that the program code which executed on the computer or otherprogrammable apparatus provide processes for implementing thefunctions/acts specified in the flowchart and/or block diagram block orblocks.

The schematic flowchart diagrams and/or schematic block diagrams in theFigures illustrate the architecture, functionality, and operation ofpossible implementations of apparatuses, systems, methods and computerprogram products according to various embodiments of the presentdisclosure. In this regard, each block in the schematic flowchartdiagrams and/or schematic block diagrams may represent a module,segment, or portion of code, which comprises one or more executableinstructions of the program code for implementing the specified logicalfunction(s).

It should also be noted that, in some alternative implementations, thefunctions noted in the block may occur out of the order noted in theFigures. For example, two blocks shown in succession may, in fact, beexecuted substantially concurrently, or the blocks may sometimes beexecuted in the reverse order, depending upon the functionalityinvolved. Other steps and methods may be conceived that are equivalentin function, logic, or effect to one or more blocks, or portionsthereof, of the illustrated Figures.

Although various arrow types and line types may be employed in theflowchart and/or block diagrams, they are understood not to limit thescope of the corresponding embodiments. Indeed, some arrows or otherconnectors may be used to indicate only the logical flow of the depictedembodiment. For instance, an arrow may indicate a waiting or monitoringperiod of unspecified duration between enumerated steps of the depictedembodiment. It will also be noted that each block of the block diagramsand/or flowchart diagrams, and combinations of blocks in the blockdiagrams and/or flowchart diagrams, can be implemented by specialpurpose hardware-based systems that perform the specified functions oracts, or combinations of special purpose hardware and program code.

The present subject matter may be embodied in other specific formswithout departing from its spirit or essential characteristics. Thedescribed embodiments are to be considered in all respects only asillustrative and not restrictive. All changes which come within themeaning and range of equivalency of the claims are to be embraced withintheir scope.

What is claimed is:
 1. A system for inspecting a component, comprising:an ultrasonic inspection probe comprising a component surface interface;a robotic device comprising an end effector coupled to the ultrasonicinspection probe, wherein the robotic device is automatably controllableto move the ultrasonic inspection probe across a surface of thecomponent; an angle sensor subsystem coupled between the ultrasonicinspection probe and the end effector, wherein the angle sensorsubsystem is configured to operably detect an actual orientation of theend effector relative to a presently inspected portion of the surface ofthe component; and a controller configured to receive orientation datafrom the angle sensor subsystem based on the actual orientation of theend effector, compare the actual orientation to a desired orientation,and control the robotic device to adjust the actual orientation of theend effector to be in the desired orientation.
 2. The system of claim 1,wherein the desired orientation comprises a longitudinal axis of the endeffector perpendicular to the presently inspected portion of the surfaceof the component.
 3. The system of claim 1, further comprising anarticulation subsystem coupled between the inspection probe and the endeffector, the articulation subsystem configured to operably maintain thecomponent surface interface properly engaged with the presentlyinspected portion of the surface of the component.
 4. The system ofclaim 3, wherein the articulation subsystem comprises a two-axis gimbalstructure coupled between the ultrasonic inspection probe and the endeffector, wherein the two-axis gimbal structure is configured topassively absorb pitch and roll movement of the ultrasonic inspectionprobe to maintain the component surface interface substantially parallelto the presently inspected portion of the surface of the component. 5.The system of claim 4, wherein the articulation subsystem furthercomprises a pneumatic actuator coupled between the two-axis gimbalstructure and the end effector, wherein the pneumatic actuator isconfigured to passively absorb movement of the ultrasonic inspectionprobe, via the two-axis gimbal structure, along an axis substantiallyperpendicular to the presently inspected portion of the surface of thecomponent.
 6. The system of claim 4, wherein the angle sensor subsystemcomprises a plurality of transducers coupled to the two-axis gimbalstructure.
 7. The system of claim 6, wherein the plurality oftransducers comprises a rotary variable differential transformer (RVDT)coupled to each axis of the two-axis gimbal structure.
 8. The system ofclaim 1, wherein the ultrasonic inspection probe comprises: a housing;an ultrasonic array coupled to the housing; a component surfaceinterface of the housing, the component surface interface comprising aliquid couplant port, an engagement lip engageable with a surface of thecomponent, and at least one vacuum port, wherein the engagement lipcircumferentially circumscribes the liquid couplant port and the atleast one vacuum port circumferentially circumscribes the engagementlip, wherein the at least one vacuum port is fluidly coupleable with avacuum source; a liquid couplant chamber disposed between the ultrasonicarray and the liquid couplant port of the component surface interface,wherein the liquid couplant chamber is in fluid communication with theliquid couplant port and the liquid couplant chamber is fluidlycoupleable with a liquid couplant supply; and an articulation subsystemcoupled to the housing and configured to operably maintain theengagement lip of the component surface interface properly engaged withthe presently inspected portion of the surface of the component.
 9. Anapparatus for inspecting a component, comprising: a housing; anultrasonic array coupled to the housing; a component surface interfaceof the housing, the component surface interface comprising a liquidcouplant port, an engagement lip engageable with a surface of thecomponent, and at least one vacuum port, wherein the engagement lipcircumferentially circumscribes the liquid couplant port and the atleast one vacuum port circumferentially circumscribes the engagementlip, wherein the at least one vacuum port is fluidly coupleable with avacuum source; a liquid couplant chamber disposed between the ultrasonicarray and the liquid couplant port of the component surface interface,wherein the liquid couplant chamber is in fluid communication with theliquid couplant port and the liquid couplant chamber is fluidlycoupleable with a liquid couplant supply; and an articulation subsystemcoupled to the housing and configured to operably maintain the componentsurface interface properly engaged with a presently inspected portion ofthe surface of the component.
 10. The apparatus of claim 9, furthercomprising a central axis extending from the ultrasonic array andthrough the liquid couplant chamber and liquid couplant port, whereinthe articulation subsystem is configured to operably maintain thecentral axis substantially perpendicular to the presently inspectedportion of the surface of the component.
 11. The apparatus of claim 9,wherein the engagement lip of the component surface interface isprotruded relative to the at least one vacuum port so as to bepositionable closer to the surface of the component relative to the atleast one vacuum port.
 12. The apparatus of claim 9, wherein the housingis coupled to an end effector of a robotic device, wherein the roboticdevice is automatably controllable to move the apparatus across thesurface of the component.
 13. The apparatus of claim 12, wherein thearticulation subsystem comprises a two-axis gimbal structure coupledbetween the housing and the end effector, wherein the two-axis gimbalstructure is configured to passively absorb pitch and roll movement ofthe housing.
 14. The apparatus of claim 13, wherein the articulationsubsystem further comprises a pneumatic actuator coupled between thetwo-axis gimbal structure and the end effector, wherein the pneumaticactuator is configured to passively absorb movement of the housing, viathe two-axis gimbal structure, along an axis substantially perpendicularto the presently inspected portion of the surface of the component. 15.The apparatus of claim 13, further comprising: an angle sensor subsystemcoupled to the two-axis gimbal structure, wherein the angle sensorsubsystem is configured to detect an actual orientation of the endeffector relative to the presently inspected portion of the surface ofthe component; and a controller configured to receive orientation datafrom the angle sensor subsystem corresponding to the actual orientationof the end effector, compare the actual orientation to a desiredorientation, and control the robotic device to adjust the actualorientation of the end effector to be in the desired orientation. 16.The apparatus of claim 15, wherein the desired orientation comprises alongitudinal axis of the end effector perpendicular to the presentlyinspected portion of the surface of the component.
 17. The apparatus ofclaim 15, wherein the angle sensor subsystem comprises a plurality oftransducers coupled to the two-axis gimbal structure.
 18. The apparatusof claim 17, wherein the plurality of transducers comprises a rotaryvariable differential transformer (RVDT) coupled to each axis of thetwo-axis gimbal structure.
 19. A method for inspecting a component,comprising: robotically moving an ultrasonic inspection probe across asurface of the component to inspect structural characteristics of thecomponent, wherein moving the ultrasonic inspection probe comprisesautomatably controlling a robotic device comprising an end effector towhich the ultrasonic inspection probe is coupled; detecting an actualorientation of the end effector relative to a presently inspectedportion of the surface of the component, wherein detecting the actualorientation of the end effector comprises receiving orientation datafrom an angle sensor subsystem that is coupled between the ultrasonicinspection probe and the end effector; comparing the actual orientationto a desired orientation; and controlling the robotic device to adjustthe actual orientation of the end effector to be in the desiredorientation.
 20. The method of claim 19, further comprising adjustingthe actual orientation of the end effector according to predeterminedorientation adjustments at predetermined locations across the surface ofthe component from a previously performed inspection of the component.